Apparatus and method for tapered core drum package payoff

ABSTRACT

Arrangements and methods for welding wire payoff sources. A tapered core and base plate, optionally along with a wire guide insert, are configured with a payout drum package and a cover containing a welding wire stack such that the welding wire may be payed off smoothly from the wire stack during an arc welding operation, without the welding wire flipping or tangling.

TECHNICAL FIELD

Certain embodiments relate to paying off a coil of wire. Moreparticularly, certain embodiments relate to arrangements and methods forpaying off wire from a welding wire stack.

BACKGROUND

Welding wire for electric arc welding is typically provided in a box ordrum referred to as a payout drum package. The wire sits in the drumpackage, for example, coiled on a reel or spool and is referred to asthe wire stack. A cover is attached to the drum package having a conduitattached to the cover. The wire is pulled through the conduit by a wirefeeder of the welding machine and is used as an electrode in electricarc welding, for example. The term “pay off” is used in the wireindustry and means pulling the wire out of the drum/box package or offthe reel/spool.

When a welding wire is withdrawn or payed off from a welding wire stackresiding in a payout drum package during an electric arc weldingoperation, for example, the spirals of the welding wire may tend to flipcausing cork screws which result in tangling of the wire. Also, thestack may move within the drum with respect to the opening in the coverwhere the conduit is attached. Such movement of the wire stack withrespect to the conduit may change the tension on the wire causing poorwire feedability and preventing smooth pay off. Such unwantedoccurrences can reduce, if not totally destroy, welding effectiveness.

Further limitations and disadvantages of conventional, traditional, andproposed approaches will become apparent to one of skill in the art,through comparison of such systems and methods with the presentinvention as set forth in the remainder of the present application withreference to the drawings.

BRIEF SUMMARY

A first embodiment of the present invention comprises a welding wirepayoff arrangement. The welding wire payoff arrangement includes a baseplate and a tapered core centrally connected to the base plate. The baseplate may include a plurality of tab receptors and the tapered core mayinclude a plurality of tabs adapted to be received into the plurality oftab receptors of the base plate to centrally connect the tapered core tothe base plate. The base plate may be substantially octagonal in shapeand the tapered core may include two slots on opposing surfaces of thetapered core for receiving a rod through the tapered core. The weldingwire payoff arrangement may include a payout drum package in which theconnected base plate and tapered core reside. A wire stack may reside inthe payout drum package such that the wire stack rests on the base plateand the tapered core protrudes through a centrally open region of thewire stack. A first diameter or width of the unconnected end of thetapered core is less than a second diameter or a second width of aconnected base end of the tapered core.

Another embodiment of the present invention comprises a method ofassembling a welding wire source. The method includes centrallyconnecting a tapered core to a base plate to form a first assembly. Themethod further includes placing the first assembly into a payout drumpackage such that the tapered core is substantially centered within thepayout drum package. The method also includes placing a coiled wirestack into the payout drum package over the tapered core such that thewire stack rests on the base plate and the tapered core protrudesthrough a centrally open region of the wire stack. The method mayfurther include inserting a holding member through the tapered core suchthat the holding member sits on top of the wire stack, and attaching atleast one tension member between the holding member and the base plateor a bottom surface of the payout drum package such that the tensionmember pulls the holding member against the wire stack. The holdingmember may comprise a steel rod and the tension member may comprise arubber band. The method may further include releasing a wire of the wirestack such that the wire spirals upward around the tapered core andfeeding an end of the released wire through an opening in a cover. Themethod may further include attaching the cover to the payout drumpackage, feeding the end of the released wire through a conduit, andattaching the conduit to the cover.

A further embodiment of the present invention comprises a welding wirepayoff arrangement. The welding wire payoff arrangement includes atapered core means for spirally guiding a wire payed off from a wirestack. The welding wire payoff arrangement further includes a base meansfor centrally supporting the tapered core means within a payout drumpackage. The base means may include at least one first connector meansfor connecting the tapered core means to the base means. The taperedcore means may include at least one second connector means forconnecting the tapered core means to the base means via the firstconnector means. The base means may be substantially octagonal in shape.The rod means may be provided for securing the wire stack within thepayout drum package. Two opening means may be present on opposingsurfaces of the tapered core means for receiving the rod means throughthe tapered core means. A first diameter or a first width of a first endof the tapered core means may be less than a second diameter or a secondwidth of a second end of the tapered core means.

These and other advantages and novel features of the present invention,as well as details of illustrated embodiments thereof, will be morefully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of an embodiment of a welding wire assembly orwelding wire source;

FIG. 2 is an exploded view of the welding wire assembly of FIG. 1;

FIG. 3 is an illustration of a side view of an embodiment of a taperedcore centrally connected to a base plate as used in the welding wireassembly of FIG. 1 and FIG. 2;

FIG. 4 is an illustration of a top view of an embodiment of the baseplate shown in FIG. 3;

FIG. 5 is an illustration of an unfolded side view of an embodiment ofthe tapered core shown in FIG. 3;

FIGS. 6A-6B are illustrations of an embodiment of a holding member and atension member as used during shipment of at least a portion of thewelding wire assembly of FIG. 1;

FIG. 7 is a flowchart of a first embodiment of a method of assembling awelding wire source for shipment;

FIG. 8 is a flowchart of a first embodiment of a method of assembling awelding wire source for use in welding;

FIG. 9 is an illustration of a first embodiment of a wire guide insertas may be used in the welding wire assemby of FIG. 1 and FIG. 2;

FIG. 10 is a flowchart of a second embodiment of a method of assemblinga welding wire source for shipment;

FIG. 11 is a flowchart of a second embodiment of a method of assemblinga welding wire source for use in welding;

FIGS. 12A-12B illustrate two unfolded views of a second embodiment of awire guide insert capable of being used in the welding wire assembly ofFIG. 1 and FIG. 2;

FIGS. 13A-13C are illustrations of several folded views of the secondembodiment of the wire guide insert of FIGS. 12A-12B; and

FIG. 14 is an illustration of a side view of an embodiment of a taperedcore centrally connected to a base plate as used in the welding wireassembly of FIG. 1 and FIG. 2.

DETAILED DESCRIPTION

FIG. 1 is an illustration of an embodiment of a welding wire assembly100 (also referred to herein as a welding wire source). FIG. 2 is anexploded view of the welding wire assembly 100 of FIG. 1. The weldingwire assembly 100 includes a payout drum package 110, a cover 120, awelding wire stack 130, a base plate 140, a tapered core 150, andoptionally a wire guide insert 160. In certain embodiments, the wireguide insert 160 may or may not be used.

The tapered core 150 is connected to the base plate 140 at a center ofthe base plate 140. The base plate 140 may be placed to rest within thepayout drum package 110 on the bottom interior surface of the payoutdrum package 110 such that the tapered core 150 is substantiallycentered within the payout drum package 110. The base plate 140 isrelatively flat and the edges of the base plate 140 fit snug against theside walls of the payout drum package 110 to prevent lateral movement ofthe base plate 140 and connected tapered core 150 within the drumpackage 110.

In accordance with an embodiment of the present invention, the baseplate 140 is octagonal in shape. Furthermore, the inner surface of thedrum package 110 may be octagonal in shape as well, as shown in FIG. 1,to match the octagonal base plate 140. Such an octagonal shape of theinterior surface of the drum package 110 helps to better hold a circularwire stack 130 in place when the outer diameter of the wire stack 130substantially matches the inner diameter or width of the octagonalinterior surface of the drum package 110.

The wire stack 130 may be placed over the tapered core 150 such that thewire stack 130 rests on the base plate 140 within the drum package 110and such that the tapered core 150 protrudes upward through a centrallyopen region 133 of the wire stack 130. The wire stack 130 has an innerdiameter and an outer diameter where the outer diameter of the wirestack 130 is substantially the same as the inner diameter or inner widthof the drum package 110 such that the wire stack 130 does not tend tomove laterally within the drum package 110.

The cover 120 attaches to the top of the drum package 110. In accordancewith an embodiment, the cover is made of a transparent plastic material.The cover 120 has an opening 125 in the top where a conduit 170 may beconnected via a connector 175. The wire from the wire stack 130 spiralsupward around the tapered core 150 and is fed through the opening 125when the wire is payed off. The conduit 170 guides the wire toward awire feeder of a welding machine, in accordance with an embodiment ofthe present invention.

As the wire is payed off from the wire stack 130, the tapered core 150remains in the center of the drum package 110. The tapered core 150 hasa first diameter or width at its top end which is smaller or less than asecond diameter or width at its base end (i.e., the tapered core istapered). The tapered core 150 provides a smooth pay off of the wirefrom the drum package 110. The tapered core 150 applies enough tensionon the wire to prevent the wire from flipping, which may cause corkscrews and tangles in the wire. Keeping the tapered core 150 centered inthe drum package 110 and, therefore, with respect to the opening 125 inthe cover 120 also helps to provide for a smooth pay off.

FIG. 3 is an illustration of a side view of an embodiment of a taperedcore 150 centrally connected to a base plate 140 as used in the weldingwire assembly 100 of FIG. 1 and FIG. 2. FIG. 4 is an illustration of atop view of an embodiment of the base plate 140 shown in FIG. 3. FIG. 5is an illustration of an unfolded side view of an embodiment of thetapered core 150 shown in FIG. 3. The unfolded tapered core 150 of FIG.5 may be folded around to form the folded tapered core 150 of FIG. 1 andFIG. 2. In accordance with an embodiment of the present invention, uponfolding around, tabs 156 may be inserted into tab receptors 157 tosecure the tapered core 150 in a folded state. Other means of securingthe tapered core 150 in a folded state are possible as well. Forexample, the one side edge of the tapered core 150 may be glued to theother side edge of the tapered core 150. The tapered core 150 may have aplurality of corrugated sides as shown in FIG. 1 and FIG. 5.

The base plate 140 may include a plurality of tab receptors 145. Thetapered core 150 may include a plurality of tabs 155 adapted to insert(be received) into the plurality of tab receptors 145 in order toconnect the tapered core 150 to the base plate 140. Again, the taperedcore 150 may be substantially centered with respect to the base plate140.

Other means may be provided to connect the tapered core 150 to the baseplate 140. For example, the tapered core 150 may be glued to the baseplate 140, or the tapered core 150 and the base plate 140 may be asingle integrated piece, such as from a mold, for example. The taperedcore 150 and base plate 140 may be made of cardboard, plastic, or anyother material suitable for providing the functionality of the taperedcore 150 and base plate 140. The tapered core 150 may be hollow orsolid, in accordance with various embodiments.

The tapered core 150 may include opposing slots 151 on each side of thetapered core 150 for accepting a holding member such as a steel rod.FIGS. 6A-6B illustrate an embodiment of a holding member 610 and atension member 620 as used during shipment of at least a portion of thewelding wire assembly 100 of FIG. 1. FIG. 6A is an exploded view of theshipping assembly 600 shown in FIG. 6B.

Again, the tapered core 150 is connected to the base plate 140 andplaced into the payout drum package 110. The wire stack 130 is placedover the tapered core 150 and into the drum package 110, resting on thebase plate 140. A holding member 610 (e.g., a steel rod) is insertedthrough the tapered core 150 via the slots 151 such that the holdingmember 610 rests on top of the wire stack 130. A tension member 620(e.g., a rubber band) is connected between the holding member 610 andthe base plate 140 or the bottom of the drum package 110 such that thetension member 620 pulls the holding member 610 against the wire stack130. This helps hold the wire stack 130 in place during shipment,helping to avoid damage to the wire stack. Alternatively, two or moretension members 620 may be used (e.g., one on each side of the holdingmember 610). The drum package 110 includes a flat lid or flat top coverto enclose the drum package 110 during shipment. The flat lid may simplycomprise four cardboard flaps attached to the sides of the drum package110 which may be folded closed.

As an example of use of a tension member 620, a first end of a rubberband may loop around the holding member 610, and a second end of therubber band may hook to a catch at the bottom of the drum package 110.An opening may be provided in the base plate 140 to provide access tothe catch. In accordance with certain embodiments of the presentinvention, the tension member 620 may be connected between the holdingmember 610 and the base plate 140 (or bottom surface of the drum package110) before the tapered core 150 is connected to the base plate 140,which may be more practical to accomplish in some embodiments.

In accordance with various embodiments, the holding member 610 maycomprise a rod of metal (e.g., steel), plastic, or some other suitablematerial. The holding member 610 may instead comprise a flat plate andthe slots 151 may be oriented horizontally instead of vertically, forexample, to accommodate the flat plate. Furthermore, in accordance withvarious embodiments, the tension member may comprise a rubber band, anelastic strap, a bungee cord, a spring, or some other suitable tensionmember.

After shipment of the assembly 600, the drum package may be opened andthe holding member 610 may be removed (e.g., by simply pulling theholding member 610 through the tapered core 150 via the slots 151) andthe wire from the wire stack 130 may be released to spiral up around thetapered core 150. Again, the end of the wire may be fed through anopening 125 in a cover 120 to which a conduit 170 is attached. The cover120 may then be secured to the top of the payout drum package 110, forexample, via clips 115 or some other securing means.

FIG. 7 is a flowchart of a first embodiment of a method 700 ofassembling a welding wire source 600 for shipment. In step 710,centrally connect a tapered core 150 to a base plate 140 to form a firstassembly. In step 720, place the first assembly into a payout drumpackage 110 such that the tapered core 150 is substantially centeredwithin the payout drum package 110. In step 730, place a coiled wirestack 130 into the payout drum package 110 over the tapered core 150such that the wire stack 130 rests on the base plate 140 and the taperedcore 150 protrudes through a centrally open region 133 of the wire stack130. In step 740, insert a holding member 610 through the tapered core150 such that the holding member 610 sits on top of the wire stack 130.In step 750, attach at least one tension member 620 between the holdingmember 610 and the base plate 140 or a bottom surface of the payout drumpackage 110 such that the tension member 620 pulls the holding member610 against the wire stack 130.

These steps may be performed in this order or in another order as may bepractical to do so. For example, the tension member 620 may be connectedbetween the holding member 610 and the base plate 140 before the taperedcore 150 is connected to the base plate 140. Furthermore, any given stepmay be divided into at least two sub-steps as may be practical to do so.For example, a first end of the tension member 620 may be firstconnected to the base plate 140, then a second end of the tension member620 may be connected to (e.g., placed around) the holding member 610.Also, an additional step or steps may be performed in between any twosuccessive steps. For example, the tension member 620 may besignificantly stretched before connecting the tension member 620 betweenthe holding member 610 and the base plate 140. Again, in accordance withvarious embodiments of the present invention, more than one tensionmember may be used. In certain embodiments, the tapered core 150 and thebase plate 140 may be a single integral piece (first assembly), such aswhen molded. In such an embodiment, the step of centrally connecting thetapered core to the base plate need not be performed.

FIG. 8 is a flowchart of a first embodiment of a method 800 ofassembling a welding wire source 100 for use in welding. In step 810,centrally connect a tapered core 150 to a base plate 140 to form a firstassembly. In step 820, place the first assembly into a payout drumpackage 110 such that the tapered core 150 is substantially centeredwithin the payout drum package 110. In step 830, place a coiled wirestack 130 into the payout drum package 110 over the tapered core 150such that the wire stack 130 rests on the base plate 140 and the taperedcore 150 protrudes through a centrally open region 133 of the wire stack130. In step 840, release a wire of the wire stack 130 such that thewire spirals upward around the tapered core 150. In step 850, feed anend of the released wire through an opening 125 in a cover 120. In step860, attach the cover 120 to the payout drum package 110. In step 870,feed the end of the released wire through a conduit 170. In step 880,attach the conduit 170 to the cover 120. The conduit 170 may attach tothe cover 120 via a male/female type screw-on connection 175, forexample.

Again, these steps may be performed in this order or in another order asmay be practical to do so. For example, the base plate 140 may be placedinto the drum package 110, and then the tapered core 150 may beconnected to the base plate 140. Furthermore, any given step or stepsmay be divided into at least two sub-steps, or combined into one step,as may be practical to do so. For example, the end of the wire may befed through both the cover 120 and the conduit 170 essentially at thesame time in a single step if the conduit 170 is first connected to thecover 120. Also, an additional step or steps may be performed in betweenany two successive steps. For example, a holding member 610 may beremoved from the tapered core 150 before releasing a wire of the wirestack 130. In certain embodiments, the tapered core 150 and the baseplate 140 may be a single integral piece (first assembly), such as whenmolded. In such an embodiment, the step of centrally connecting thetapered core to the base plate need not be performed.

FIG. 9 is an illustration of a first embodiment of a wire guide insert160 as may be used in the welding wire assembly 100 of FIG. 1 and FIG.2. The wire guide insert 160 (also generically referred to as a weldingwire payoff arrangement herein) includes a base portion 910 having afirst opening 911 located substantially in a central location of thebase portion 910. The wire guide insert 160 also includes a top portion920 being spatially offset from the base portion 910 and having a secondopening 921 being smaller than the first opening 911, and beingsubstantially aligned with the first opening 911 as shown by the dashedline 915. The wire guide insert 160 further includes an offset portion930 connected between the top portion 920 and the base portion 910 formaintaining a spatial offset 935 between the top portion 920 and thebase portion 910.

In accordance with an embodiment of the present invention, the baseportion 910 is substantially longer than the top portion 920 and thebase portion 910 is substantially parallel to the top portion 920. Theoffset portion 930 is angled with respect to the parallel top and baseportions such that the top portion 920, the base portion 910, and theoffset portion 930 characterize a substantially truncated triangularvolume.

In accordance with an embodiment of the present invention, the offsetportion 930 and the top portion 920 may be all one integral piece whichis then connected to the base portion 910 (e.g., by snapping orglueing). As an alternative, the base portion 910, the offset portion930, and the top portion 920 may all be one integral piece. Otherpiecewise or integral constructions are possible as well thatcharacterize a substantially truncated triangular volume.

Referring to FIG. 1 and FIG. 2, the top portion 920 may be connectedinside the cover 120 such that the opening 921 is adjacent to andsubstantially aligned with the opening 125 in the cover 120. The wirefrom the wire stack 130 may be fed upward from around the tapered core150, through the opening 911, through the opening 921, and through theopening 125 and into the conduit 170.

When connected to the cover 120, the angled offset portions 930 of thewire guide insert 160 substantially follow a contour of an interiorsurface of the cover 120. This allows the wire guide insert 160 to justfit up into the interior of the cover 120. The base portion 910 of thewire insert guide 160 helps to hold the spirals of wire off of the wirestack 130 down around the tapered core 150, helping to provide thedesired tension on the wire for smooth pay off. The wire guide insert160 effectively bridges the gap across the inside of the cover 120 toprevent the wire loops (spirals) from springing up. The wire guideinsert 160 may be made of thermoformed plastic or cardboard, or anyother suitable material.

FIG. 10 is a flowchart of a second embodiment of a method 1000 ofassembling a welding wire source for shipment. In step 1010, centrallyconnect a tapered core 150 to a base plate 140 to form a first assembly.In step 1020, place the first assembly into a payout drum package 110such that the tapered core 150 is substantially centered and laterallyimmovable within the payout drum package 110. In step 1030, place acoiled wire stack 130 into the payout drum package 110 over the taperedcore 150 such that the wire stack 130 rests on the base plate 140 andthe tapered core 150 protrudes upward through a centrally open region133 of the wire stack 130.

In step 1040, connect a wire guiding structure 160, having a baseportion 910 which is longer than a top portion 920, to an interiorportion of a cover 120 such that a first opening 911 in the base portion910, a second opening 921 in the top portion 920, and a third opening125 in the cover are substantially aligned. In step 1050, insert aholding member 610 through the tapered core 150 such that the holdingmember 610 sits on top of the wire stack 130. In step 1060, attach atleast one tension member 620 between the holding member 610 and the baseplate 140 or a bottom surface of the payout drum package 110 such thatthe tension member 620 pulls the holding member 610 against the wirestack 130.

Again, these steps may be performed in this order or in another order asmay be practical to do so. For example, the tension member 620 may beconnected between the holding member 610 and the base plate 140 beforethe tapered core 150 is connected to the base plate 140. Furthermore,any given step may be divided into at least two sub-steps as may bepractical to do so. For example, a first end of the tension member 620may be first connected to the base plate 140, then a second end of thetension member 620 may be connected to (e.g., placed around) the holdingmember 610. Also, an additional step or steps may be performed inbetween any two successive steps. For example, the tension member 620may be significantly stretched before connecting the tension member 620between the holding member 610 and the base plate 140. Again, inaccordance with various embodiments of the present invention, more thanone tension member may be used. In certain embodiments, the tapered core150 and the base plate 140 may be a single integral piece (firstassembly), such as when molded. In such an embodiment, the step ofcentrally connecting the tapered core to the base plate need not beperformed.

FIG. 11 is a flowchart of a second embodiment of a method 1100 ofassembling a welding wire source 100 for use in welding. In step 1110,centrally connect a tapered core 150 to a base plate 140 to form a firstassembly. In step 1120, place the first assembly into a payout drumpackage 110 such that the tapered core 150 is substantially centered andlaterally immovable within the payout drum package 110. In step 1130,place a coiled wire stack 130 into the payout drum package 110 over thetapered core 150 such that the wire stack 130 rests on the base plate140 and the tapered core 150 protrudes upward through a centrally openregion 133 of the wire stack 130.

In step 1140, connect a wire guiding structure 160, having a baseportion 910 which is longer than a top portion 920, to an interior sideof a cover 120 such that a first opening 911 in the base portion 910, asecond opening 921 in the top portion 920, and a third opening 125 inthe cover 120 are substantially aligned. In step 1150, release a wire ofthe wire stack 130 such that the wire spirals upward around the taperedcore 150. In step 1160, feed an end of the released wire through thefirst opening 911, the second opening, 921, and the third opening 125.In step 1170, attach the cover 120 to the payout drum package 110. Instep 1180, feed the end of the release wire through a conduit 170. Instep 1190, attach the conduit 170 to the cover 120 adjacent to the thirdopening 125. The conduit 170 may attach to the cover 120 via amale/female type screw-on connection 175, for example.

Again, these steps may be performed in this order or in another order asmay be practical to do so. For example, the base plate 140 may be placedinto the drum package 110, and then the tapered core 150 may beconnected to the base plate 140. Furthermore, any given step or stepsmay be divided into at least two sub-steps, or combined into one step,as may be practical to do so. For example, the end of the wire may befed through both the cover 120 and the conduit 170 essentially at thesame time in a single step if the conduit 170 is first connected to thecover 120. Also, an additional step or steps may be performed in betweenany two successive steps. For example, a holding member 610 may beremoved from the tapered core 150 before releasing a wire of the wirestack 130. In certain embodiments, the tapered core 150 and the baseplate 140 may be a single integral piece (first assembly), such as whenmolded. In such an embodiment, the step of centrally connecting thetapered core to the base plate need not be performed.

FIGS. 12A-12B are illustrations of two unfolded views of a secondembodiment of a wire guide insert 1200 capable of being used in thewelding wire assembly 100 of FIG. 1 and FIG. 2. The wire guide insert1200 performs the same function in the welding wire source 100 as thewire guide insert 160 previously described herein. FIG. 12A is a topview and FIG. 12B is a perspective view.

The wire guide insert 1200 (also generically referred to as a weldingwire payoff arrangement or welding wire structure herein) includes abase means 1210 for holding down spirals of coiled wire payed off from awire stack 130 within a payout drum package 110. The base means 1210 hasa first opening 1211 for guiding the wire through the base means 1210 asthe wire is payed off from the wire stack 130. The wire guide insert1200 also includes a first top means 1220 offset from the base means1210 for receiving the wire from the base means 1210 as the wire ispayed off. The first top means 1220 has a second opening 1221 forguiding the wire through the first top means 1220 toward a cover 120 ofthe payout drum package 110 as the wire is payed off. The cover 120 hasa fourth opening means 125 as previously described herein.

The wire guide insert 1200 also includes a first offset means 1230hingedly connecting the base means 1210 to the first top means 1220 athinged points 1231 and 1232. The wire guide insert 1200 further includesa second top means 1240 spatially offset from the base means 1210 forreceiving the wire from the first top means 1220 as the wire is payedoff. The second top means 1240 has a third opening means 1241 forguiding the wire through the second top means 1240 toward the cover 120as the wire is payed off. The wire guide insert 1200 also includes asecond offset means 1250 hingedly connecting the base means 1210 to thesecond top means 1240 at hinged points 1251 and 1252.

The base means 1210 is substantially longer than either of the top means1220 or 1240. The length and other dimensions of the first top means1220 and the second top means 1240 are substantially the same. The basemeans 1210, the first offset means 1230, the second offset means 1250,the first top means 1220, and the second top means 1240 are capable ofbeing hingedly unfolded with respect to each other to characterize asubstantially outstretched surface as shown in FIGS. 12A-12B. Such anoutstretched configuration may result when manufacturing the wire guideinsert 1200, and the wire guide insert 1200 may be shipped (not yetconnected to a cover 120) in such an outstretched manner.

FIGS. 13A-13C are illustrations of several folded views of the secondembodiment of the wire guide insert 1200 of FIGS. 12A-12B, as would beused in the welding wire arrangement 100 of FIGS. 1-2. The base means1210, the first offset means 1230, the second offset means 1250, thefirst top means 1220, and the second top means 1240 are capable of beinghingedly folded with respect to each other to characterize asubstantially truncated triangular volume as shown in FIGS. 13A-13C.

The hinged points 1231, 1232, 1251 and 1252 may comprise, for example,flexible plastic that is easily folded or may comprise actual hingesthat are connected between the base means and offset means and theoffset means and the top means. In accordance with an embodiment of thepresent invention, the wire guide insert 1200 is all one molded piecemade of a plastic material. Other materials are possible as well suchas, for example, cardboard.

The opening means 1211 is substantially larger than either of theopening means 1221 and 1241, in accordance with an embodiment of thepresent invetion. When folded, the first top means 1220, the second topmeans 1240, and the cover 120 are capable of being configured such thatthe first opening means 1211, the second opening means 1221, the thirdopening means 1241, and the fourth opening means 125 are substantiallyaligned. The wire guiding structure 1200 connects to the cover 120 inmuch the same manner as the wire guiding insert 160 (see FIGS. 1-2) andserves the same purpose.

When folded, the second top means 1240 overlaps onto the first top means1220 and may snap onto the first top means 1220 to hold the structure1200 together in the folded configuration. As an alternative, the twotop means 1220 and 1240 may be held together only when installed in theinterior of the cover 120 by, for example, a connector 175 having, forexample, a bolt and nut assembly.

In accordance with an alternative embodiment, the wire guide insert 1200may be manufactured as a single molded piece, already in the foldedconfiguration and not having any hinged connections. Similarly, the wireguide insert 1200 may be manufactured as a plurality of pieces (e.g., abase means 1210, a first offset means 1230, a second offset means 1250,and a top means 1220) that are connected (e.g., snapped) together tocharacterize the substantially truncated triangular volume. Otherpiecewise or integral constructions are possible as well.

In summary, arrangements and methods are disclosed for welding wirepayoff sources. A tapered core and base plate, optionally along with awire guide insert, may be configured with a payout drum package and acover containing a welding wire stack such that the welding wire ispayed off smoothly from the wire stack during an arc welding operation,without the welding wire flipping or tangling.

While the invention has been described with reference to certainembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the invention without departing from its scope.Therefore, it is intended that the invention not be limited to theparticular embodiment disclosed, but that the invention will include allembodiments falling within the scope of the appended claims.

1. A welding wire payoff arrangement, said arrangement comprising: abase plate; a vertically oriented folded tapered core centrallyconnected to said base plate, wherein said folded tapered core includestwo opposing and substantially circumferentially-oriented slots locatedabove a top of a wire stack surrounding the core, and wherein saidfolded tapered core is initially flat in its unfolded state; and a wireguide insert positioned above said tapered core, said wire guide insertincluding a base portion, a first opening through said base portion, atop portion being spatially offset from said base portion, a secondopening through said top portion, and an offset portion connectedbetween said top portion and said base portion for maintaining a spatialoffset between said base portion and said top portion.
 2. The weldingwire payoff arrangement of claim 1 wherein said base plate includes aplurality of tab receptors.
 3. The welding wire payoff arrangement ofclaim 2 wherein said tapered core includes a plurality of tabs adaptedto be received into said plurality of tab receptors to centrally connectsaid tapered core to said base plate.
 4. The welding wire payoffarrangement of claim 1 wherein said base plate is substantiallyoctagonal in shape.
 5. The welding wire payoff arrangement of claim 1further comprising a rod capable of being received through said twoopposing slots of said folded tapered core.
 6. The welding wire payoffarrangement of claim 1 further comprising a payout drum package in whichsaid tapered core and said base plate reside.
 7. The welding wire payoffarrangement of claim 6 further comprising a wire stack residing withinsaid payout drum package such that said wire stack rests on said baseplate and said tapered core protrudes through a centrally open region ofsaid wire stack.
 8. The welding wire payoff arrangement of claim 1wherein a first diameter or a first width of an unconnected end of saidtapered core is less than a second diameter or a second width of aconnected base end of said tapered core.
 9. A method of assembling awelding wire source, said method comprising: centrally connecting avertically oriented folded tapered core to a base plate to form a firstassembly, wherein said folded tapered core includes two opposing andsubstantially circumferentially-oriented slots located above a top of acoiled wire stack surrounding the core, and wherein said folded taperedcore is initially flat in its unfolded state; placing the first assemblyinto a payout drum package such that said tapered core is substantiallycentered within said payout drum package; placing the coiled wire stackinto said payout drum package over said tapered core such that said wirestack rests on said base plate and said tapered core protrudes through acentrally open region of said wire stack; releasing a wire of said wirestack such that said wire spirals upward around said tapered core; andfeeding an end of said released wire through a wire guide insert havinga base portion, a first opening through said base portion, a top portionbeing spatially offset from said base portion, a second opening throughsaid top portion, and an offset portion connected between said topportion and said base portion for maintaining a spatial offset betweensaid base portion and said top portion.
 10. The method of claim 9further comprising: feeding said end of said released wire through anopening in a cover, wherein said cover is a transparent plasticmaterial; attaching said wire guide insert to said cover; attaching saidcover to said payout drum package, wherein said attaching said cover tosaid payout drum package is via clips; feeding said end of said releasedwire through a conduit; and attaching said conduit to said cover. 11.The method of claim 9 further comprising: inserting a holding memberthrough said opposing slots of said folded tapered core such that saidholding member sits on top of said wire stack; and attaching at leastone tension member between said holding member and said base plate or abottom surface of said payout drum package such that said tension memberpulls said holding member against said wire stack.
 12. The method ofclaim 11 wherein said holding member comprises a steel rod.
 13. Themethod of claim 11 wherein said tension member is selected from thegroup consisting of a bungee cord and a spring.
 14. A welding wirepayoff arrangement, said arrangement comprising: vertically orientedfolded tapered core means for spirally guiding a wire payed off from awire stack, wherein said folded tapered core means includes two opposingand substantially circumferentially-oriented slots means located above atop of the wire stack surrounding the core means, and wherein saidfolded tapered core means is initially flat in its unfolded state; basemeans for centrally supporting said tapered core means within a payoutdrum package; and wire guide insert means having a base portion forholding down spirals of a coiled wire and for receiving an end of saidcoiled wire through said base portion.
 15. The welding wire payoffarrangement of claim 14 wherein said base means includes at least onefirst connector means for connecting said tapered core means to saidbase means.
 16. The welding wire payoff arrangement of claim 15 whereinsaid tapered core means includes at least one second connector means forconnecting said tapered core means to said base means via said firstconnector means.
 17. The welding wire payoff arrangement of claim 14wherein said base means is substantially octagonal in shape.
 18. Thewelding wire payoff arrangement of claim 14 further comprising a rodmeans for securing said wire stack within said payout drum package. 19.The welding wire payoff arrangement of claim 18 wherein said rod meansis capable of being received through said two opposing slots of saidfolded tapered core means.
 20. The welding wire payoff arrangement ofclaim 14 wherein a first diameter or a first width of a first end ofsaid tapered core means is less than a second diameter or a second widthof a second end of said tapered core means.